US9574259B2 - Method for producing high-strength magnesium alloy material and magnesium alloy rod - Google Patents

Method for producing high-strength magnesium alloy material and magnesium alloy rod Download PDF

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US9574259B2
US9574259B2 US14/129,562 US201214129562A US9574259B2 US 9574259 B2 US9574259 B2 US 9574259B2 US 201214129562 A US201214129562 A US 201214129562A US 9574259 B2 US9574259 B2 US 9574259B2
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workpiece
magnesium alloy
mold
inner space
mpa
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US20140147331A1 (en
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Hiromi Miura
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University of Electro Communications NUC
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F3/00—Changing the physical structure of non-ferrous metals or alloys by special physical methods, e.g. treatment with neutrons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/02—Preliminary treatment of metal stock without particular shaping, e.g. salvaging segregated zones, forging or pressing in the rough
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C22C23/02—Alloys based on magnesium with aluminium as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/06—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of magnesium or alloys based thereon

Definitions

  • the present invention relates to a method for producing a high-strength magnesium alloy material.
  • Magnesium alloys are lightweight and have high specific strength. As such, they are expected to be widely used as next-generation lightweight structural materials.
  • magnesium alloys are hard-to-work materials that are known to easily crack or produce defects in the case where conventional processes such as a rolling process or forging are used.
  • improving the strength of a magnesium alloy material through a work hardening process has been a challenge, and application fields of magnesium alloy materials have been limited to small electronic equipment components and similar applications in which material strength is not such an important factor.
  • Non-Patent Documents 1 and 2 In recent years, techniques have been disclosed for improving the strength of magnesium alloys by adding transition metals and certain rare earth metals to magnesium (see e.g., Non-Patent Documents 1 and 2).
  • Non-Patent Documents 1 and 2 are also referred to as KUMADAI magnesium alloy.
  • alloy strength is improved by adding rare earth metal elements and causing the development of a special atomic structure (long-period stacking ordered structure) within the alloy structure.
  • Non-Patent Documents 1 and 2 may be limited to high-quality value-added products.
  • a method for producing a high-strength magnesium alloy material includes:
  • step (b) is performed while suppressing deformation of the workpiece widening outward under conditions including
  • a plastic deformation rate is less than or equal to 10%
  • a strain rate is less than or equal to 0.1/sec.
  • the plastic deformation rate is defined by a change ratio of the volume of the workpiece before and after the forging process.
  • the strain rate is defined by the initial strain rate.
  • a mold having an inner space for accommodating the workpiece is used in step (b), and the inner space is formed by an inner wall of the mold.
  • L denotes the maximum dimension of the top face of the workpiece
  • P denotes the maximum gap between the side face of the workpiece and the inner wall of the mold
  • the ratio (L:P) may be within a range from 20:1 to 600:1.
  • the inner space of the mold is formed by assembling a plurality of mold members.
  • the inner space does not have to penetrate through the mold.
  • a size of the inner space may vary along its depth direction.
  • a magnesium alloy rod has a longitudinal direction substantially parallel to the c-axis direction.
  • a magnesium alloy material produced by one of the above methods of the present invention is provided.
  • the magnesium alloy material may have the shape of a rod, a plate, a block, or a pellet, or a tube.
  • a comparatively simple and inexpensive method for producing a high-strength magnesium alloy material may be provided.
  • FIG. 1 is a flowchart illustrating a method for producing a high-strength magnesium alloy material according to an embodiment of the present invention
  • FIG. 2 illustrates an exemplary configuration of a workpiece
  • FIG. 3 illustrates an exemplary apparatus for implementing the method according to an embodiment of the present invention
  • FIG. 4 illustrates structures (optical micrographs) of the workpiece before and after a forcing process according to an embodiment of the present invention is performed
  • FIG. 5 is a graph illustrating an exemplary relationship between a compressive load ⁇ p applied to the workpiece and the hardness of the workpiece;
  • FIG. 6 illustrates a configuration of another mold that may be used in an embodiment of the present invention
  • FIG. 7 illustrates a configuration of yet another mold that may be used in an embodiment of the present invention.
  • FIG. 8 illustrates configurations of mold members 665 A and 665 B that are used in the mold illustrated in FIG. 7 ;
  • FIG. 9 illustrates a configuration of another press mandrel that may be used in an embodiment of the present invention.
  • FIG. 10 illustrates an exemplary use mode of the press mandrel illustrated in FIG. 9 ;
  • FIG. 11 illustrates other exemplary configurations of the press mandrel and/or the base member that may be used in an embodiment of the present invention
  • FIG. 12 is a graph illustrating measurement results of a compressive stress-strain curve in the longitudinal direction of a pre-forging sample
  • FIG. 13 illustrates results of measuring texture changes in the pre-forging sample (initial material) and sample 5 obtained through orientation imaging microscopy observation;
  • FIG. 14 is a graph illustrating compressive stress-strain curves of samples processes under different conditions and the compressive stress-strain curve of the pre-forging sample obtained through tensile testing.
  • magnesium alloy materials have poor workability so that they may easily crack or incur defects when conventional work processes such as forging or a cold rolling process are performed thereon.
  • conventional work processes such as forging or a cold rolling process are performed thereon.
  • a large amount of distortion cannot be introduced, and improving the strength of the magnesium alloy material through a work hardening process has been difficult.
  • rare earth metal elements have to be added at a weight ratio of approximately 5% to 7% or higher to control the alloy composition. Also, these rare earth metal elements are generally expensive. Thus, magnesium alloys obtained using the above techniques may become expensive as well. Further, the use of rare earth metal elements is not very favorable from the standpoint of securing a stable supply of materials.
  • a method for producing a high-strength magnesium alloy material conceived by the inventors of the present invention does not require adding such expensive rare earth metal elements to control the alloy composition.
  • a high-strength magnesium alloy may be produced through a forging process. In this way, a high-strength magnesium alloy may be produced by a comparatively simple and inexpensive method.
  • a method for producing a high-strength magnesium alloy material includes:
  • step (b) is performed while suppressing deformation of the workpiece widening outward under conditions including
  • a plastic deformation rate is 10% or less
  • a strain rate is 0.1/sec or less.
  • a heavy compressive load ⁇ p that satisfies formula (1) indicated below is applied to the workpiece.
  • Forging processes are generally not performed under the above condition on workpieces made of hard-to-work materials. That is, when a heavy compressive load ⁇ p as described above is applied to the workpiece, the workpiece is prone to break.
  • a heavy compressive load ⁇ p satisfying the above formula (1) may be applied to the workpiece without causing the magnesium alloy material workpiece to break.
  • this is achieved by performing a forging process “slowly” while the side face of the workpiece is “constrained” and the plastic deformation rate is restricted to a small value.
  • the side face of the workpiece is “constrained,” the strain rate is adjusted to be less than or equal to 0.1/sec, and the plastic deformation rate is adjusted to be less than or equal to 10%.
  • a uniaxial forging process may be performed on the workpiece while preventing the workpiece from cracking or breaking even when applying a heavy compressive load ⁇ p satisfying the above formula (1) to the workpiece.
  • strain of the side face of the workpiece or to “constrained” deformation of the side face of the workpiece refers to suppressing free deformation of the side face of the workpiece during a forging process.
  • the expression may refer to suppressing deformation of the side face of the workpiece widening outward from its original position.
  • a large number of deformation twins may be introduced into the crystal structure and dislocation density may be improved by slip deformation. In this way, work hardening through the forging process may be enabled and the strength of the workpiece may be increased.
  • the compressive load ⁇ p applied to the workpiece may be any value that satisfies formula (1).
  • the compressive load ⁇ p is preferably set as high as possible to obtain greater strength improvement effects.
  • the compressive load ⁇ p may be arranged to be ⁇ p ⁇ 2.4 ⁇ f, and more preferably ⁇ p ⁇ 3 ⁇ f.
  • the compressive load ⁇ p is arranged to satisfy formula (2) indicated below. ⁇ p ⁇ 10 ⁇ f (2)
  • FIG. 1 is a flowchart illustrating a method for producing a high strength magnesium alloy material according to an embodiment of the present invention.
  • the method for producing a high-strength magnesium alloy material according to the present embodiment includes:
  • step S 110 (a) a step of preparing a magnesium alloy workpiece having a top face and a side face (step S 110 );
  • step S 120 a step of applying a compressive load ⁇ p from the top face side of the workpiece and performing a uniaxial forging process on the workpiece (step S 120 ); wherein step (b) is performed under the conditions indicated below
  • plastic deformation rate is 10% or less
  • a magnesium alloy workpiece is prepared.
  • the workpiece 110 has a substantially cylindrical shape and includes a top face 112 , a side face 114 , and a bottom face 116 .
  • the configuration illustrated in FIG. 2 is merely one example, and the workpiece 110 may have other shapes and configurations.
  • the workpiece 110 may be arranged into a rod, a block, a conical shape, a truncated conical shape, a pyramidal shape, a truncated pyramid shape, a plate (including a disk), a pellet shape, or a tubular shape. That is, the workpiece 110 may be arranged into any shape that includes a top face and a side face.
  • top face and “side face” are used to describe relative locations of the workpiece. That is, the “top face” refers to a face of the workpiece that comes into contact with a press mandrel (member for applying a compressive load to the workpiece) while a forging process is performed on the workpiece.
  • the “top face” is substantially perpendicular to the direction in which the compressive load is applied.
  • the “side face” of the workpiece refers to a face that is adjacent to the “top face” of the workpiece.
  • the “top surface” refers to one end face of the workpiece
  • the “side face” refers to at least one of a plurality of faces extending in the longitudinal direction of the workpiece.
  • the “upper face” of the workpiece refers to one end face of the work piece having a tubular opening
  • the “side face” refers to an outer peripheral face and/or an inner peripheral face of tubular structure extending in the longitudinal direction.
  • the workpiece 110 is made of a magnesium alloy material.
  • the material of the workpiece 110 is not particularly limited as long as it includes a magnesium alloy.
  • an AZ-based magnesium alloy magnesium alloy containing zinc and aluminum
  • a rare-earth-element-doped magnesium alloy or a Ca-doped magnesium alloy may be used as the material of the workpiece 110 .
  • FIG. 3 illustrates an exemplary configuration of an apparatus 200 that may be used in the method for producing a high-strength magnesium alloy material according to an embodiment of the present invention.
  • the apparatus 200 used in the present embodiment includes a mold 220 having an inner space 215 , a base member 230 arranged at a bottom portion of the inner space 215 of the mold 220 , and a press mandrel 240 .
  • the base member 230 may be omitted.
  • the mold 220 has an inner wall 225 that forms the inner space 215 .
  • the press mandrel 240 is pressed against the top face 112 of the workpiece 110 , and the press mandrel 240 moves along the longitudinal direction of the workpiece 110 (Z direction of FIG. 3 ). In this way, a compressive load ⁇ p (MPa) may be applied to the workpiece 110 .
  • MPa compressive load
  • the compressive load ⁇ p (MPa) applied to the workpiece 110 satisfies formula (1) indicated below. ⁇ p> ⁇ f (1)
  • the side wall 114 of the workpiece 110 may be “constrained” by the inner wall 225 of the mold 220 or prevented from deforming outward to a large extent (such deformation being referred to as “constrained deformation” hereinafter).
  • the strain rate of the workpiece 110 is controlled to be less than or equal to 0.1/sec, and the plastic deformation rate of the workpiece 110 is controlled to be less than or equal to 10%.
  • the plastic deformation rate of the workpiece 110 may be adjusted to be within a range from 2% to 8%.
  • a heavy compressive load ⁇ p may be applied to the workpiece 110 without causing the workpiece 110 to break or incur defects.
  • the gap P between the workpiece 110 and the inner wall 225 may vary depending on the plastic deformation rate and/or the maximum length of the top face 112 of the workpiece 110 (denoted as “L”).
  • a ratio of the gap P to the maximum length L of the top face 112 of the workpiece 110 may be arranged to be within a range from 1:20 to 1:600. (Note that a total gap between the inner wall 225 and the workpiece 110 with respect to a direction parallel to the top face 112 (XY plane) equals 2P at the maximum.)
  • a large number of deformation twins may be introduced into the crystal structure and dislocation density may be improved by slip deformation.
  • work hardening through the forging process may be enabled and the strength of the workpiece 110 may be increased after the forging process.
  • FIG. 4 illustrates exemplary structures (optical micrographs) of a workpiece before and after a forging process according to the present embodiment is performed.
  • the micrograph on the left side of FIG. 4 illustrates the state of the workpiece before the forging process is performed.
  • more deformation twins may be introduced into the crystal structure as the compressive load ⁇ p is increased. Also, no significant change in the crystal grain structure can be observed other than the introduction of the deformation twins. Based on the above, it may be understood that in the present embodiment, the initial crystal grain structure may remain substantially intact, and a large number of deformation twins may be introduced in such a state.
  • FIG. 5 is a graph illustrating an exemplary relationship between the compressive load ⁇ p applied to the workpiece and the hardness of the workpiece. Note that in the present example, a workpiece made of an AZ-based magnesium alloy (8 wt % Al-wt % Zn—Mg) was used, and the strain rate of the workpiece was adjusted to 10 ⁇ 3 /sec. Also, the ratio (P:L) during the forging process was adjusted to be 1:102.
  • the mold 420 has an inner space 415 that is capable of accommodating a truncated conical shaped workpiece 310 .
  • FIGS. 7 and 8 illustrate an exemplary configuration of another mold 620 that may be used in the present embodiment.
  • a workpiece may be easily removed from the mold 620 after the forging process.
  • the inner mold 660 and the inner space 615 have substantially cylindrical shapes.
  • the shapes and configurations of the inner mold 660 and the inner space 615 are not limited to the illustrated example.
  • the inner mold 660 and the inner space 615 may have conical shapes with their diameters becoming smaller from one end to the other end in the longitudinal direction (i.e., tapered shape).
  • the outer periphery of the inner mold 660 may be tapered. In this way, removal of the mold members 665 A and 665 B and the workpiece from the outer housing 650 after the forging process may be further facilitated.
  • the number of mold members making up the inner mold 660 is not particularly limited. That is, the inner mold 660 may be formed by assembling three or more mold members, for example.
  • the configurations of the press mandrel and/or the base member are not limited to those having flat contact faces that respectively come into contact with the top face and the bottom face of the workpiece.
  • FIGS. 9 and 10 illustrate an exemplary configuration of another press mandrel 940 that may be used in the present embodiment.
  • the press mandrel 940 includes an upper part 942 and an extension part 943 that is coupled to the upper part 942 .
  • the extension part 943 extends along the axial direction of the press mandrel 940 .
  • the press mandrel 940 with the above configuration may be suitably used in a case where the workpiece has a tubular shape.
  • FIG. 10 illustrates an exemplary configuration of an apparatus that uses the above press mandrel 940 .
  • the apparatus includes a mold 820 having an inner space 815 defined by an inner wall 825 .
  • a workpiece 710 having a tubular shape is arranged inside the inner space 815 .
  • the workpiece 710 is placed above a base member 830 of the mold 820 .
  • the press mandrel 940 as illustrated in FIG. 9 is arranged above the workpiece 710 with the extension part 943 penetrating through a through hole of the workpiece 710 .
  • the workpiece 710 may be compressively deformed.
  • deformation of an outer periphery side face of the workpiece 710 is “constrained” such that the outer periphery side face of the workpiece 710 can only be deformed (widened) outward up to a point where the gap between the outer periphery side face of the workpiece 710 and the inner wall 825 closes.
  • deformation of an inner periphery side face of the workpiece 710 is “constrained” by the extension part 943 of the press mandrel 940 such that the workpiece 710 can only be deformed up to a point where a gap between the inner periphery side face of the workpiece 710 and the extension part 943 of the press mandrel 940 closes.
  • “constrained deformation” may be implemented with respect to the overall configuration of the workpiece 710 during the forging process so that the through hole of the workpiece 710 may be prevented from closing and the overall strength of the workpiece 710 may be increased.
  • FIG. 11 illustrates other exemplary configurations of the press mandrel and/or base member.
  • a press mandrel 1041 has a convex part 1041 P arranged at a contact face that comes into contact with a workpiece, and a base member 1031 has a concave part 1031 C arranged at a contact face that comes into contact with the workpiece.
  • a press mandrel 1042 has a concave part 1042 C arranged at a contact face that comes into contact with a workpiece, and a base member 1032 has a convex part 1032 P arranged at a contact face that comes into contact with the workpiece.
  • the contact face of the press mandrel may be arranged flat and the contact face of the base member may be arranged to have a convex part or a concave part.
  • the contact face of the base member may be arranged flat and the contact face of the press mandrel may have a convex part or a concave part.
  • the apparatus used in the present embodiment may have numerous other configurations.
  • the inner space for accommodating a workpiece may be arranged to have a relatively simple configuration as described above, or alternatively, the inner space may have a more complicated configuration approximating the outer shape of a final molded product, for example.
  • the gap P between the side face of the workpiece and the inner wall of the mold may be arranged to vary in the depth direction (forging direction), for example.
  • Disk-shaped samples were prepared from a commercially available AZ80 magnesium alloy rod produced by hot extrusion (by Osaka Fuji Corporation). The samples were arranged to have a diameter L of 25.5 mm and a total length of 16 mm.
  • FIG. 12 is a graph illustrating measurement results of the compressive stress-strain curve in the longitudinal direction of the sample before a forging process was performed (pre-forging sample). Note that the present experiment was conducted under room temperature, and the initial strain rate was adjusted to 3.0 ⁇ 10 ⁇ 3 /sec. Also, in this experiment, deformation of the sample was not constrained, and the sample was able to freely expand and widen outward during compression.
  • the compressive breaking stress of the pre-forging sample under the above conditions where deformation is not constrained is approximately 400 MPa.
  • the sample was arranged within an inner space of a mold.
  • the inner space penetrates through the mold and has a circular disk shape with a diameter of 26 mm and a total length of 16 mm.
  • the gap P between the side face of the sample and the inner wall of the mold was 0.25 mm.
  • the press mandrel has a diameter of 25.5 mm.
  • the compressive load ⁇ p was varied with respect to each testing sample. Specifically, the compressive load ⁇ p was adjusted to 566 MPa, 754 MPa, 943 MPa, 1320 MPa, and 1509 MPa.
  • the above compressive loads correspond to cases where the ratio ⁇ p/ ⁇ f is approximately 1.4, approximately 1.9, approximately 2.4, approximately 3.3, and approximately 3.8, respectively.
  • FIG. 4 illustrates micrographs of samples 2 and 5 along with a micrograph of the pre-forging sample. Note that in FIG. 4 , arrow LA represents the forging direction of the samples.
  • deformation twins introduced into the structure may be increased, as the compressive load ⁇ p during the forging process is increased.
  • FIG. 13 illustrates measurement results of texture changes in the pre-forging sample (initial material) and sample 5 obtained through OIM by (Orientation Imaging Microscopy) observation.
  • FIG. 13 ( a ) illustrates the crystal orientation distribution of the initial material
  • FIG. 13 ( b ) illustrates the crystal orientation distribution of sample 5.
  • observation of the initial material was made with respect to a cross-section of the initial material perpendicular to the extrusion direction.
  • the observation of sample 5 was made with respect to a cross-section perpendicular to the compression direction.
  • a darker region represents a region with a higher crystal orientation distribution in the corresponding direction
  • a lighter region represents a region with a lower crystal orientation distribution.
  • crystals are aligned primarily in a direction perpendicular to the c-axis direction (0001), particularly, the crystal orientation (1010).
  • Such characteristics are typical of hot extruded materials. That is, in the rod-shaped hot extruded material (initial material), the c-axis tends to be oriented in a direction perpendicular to the longitudinal direction of the rod.
  • crystals are aligned primarily in the crystal orientation (0001); namely, the c-axis direction. That is, in sample 5, the c-axis (0001) tends to be oriented parallel to the compression direction. This indicates that the c-axis direction is oriented parallel to the longitudinal direction of the rod.
  • a crystal rotation may be triggered only when substantial plastic deformation occurs in a material.
  • a forging process may be performed on a workpiece without breaking the workpiece, and crystal rotation may occur after the forging process.
  • FIG. 14 is a graph illustrating the true stress-nominal strain curves of sample 1 and samples 3-5.
  • FIG. 14 also illustrates the true stress-nominal strain curve of the pre-forging sample.
  • the maximum tensile strength of each of the above samples exceeds 400 Mpa and is improved compared to the maximum tensile strength of the pre-forging sample (maximum tensile strength of approximately 350 Mpa). Further, the yield stress of each of the above samples is greater than or equal to 250 Mpa and is improved from the yield stress of the pre-forging sample (yield stress of approximately 100 MPa)

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PCT/JP2012/065666 WO2013002082A1 (ja) 2011-06-28 2012-06-19 高強度マグネシウム合金材料を製造する方法およびマグネシウム合金製の棒材

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